PendoTECH Bioreactor Control SystemTM
• For use with single use or glass bioreactors• Complete process control, by PID control of gases, base addition and temperature • Ability to use traditional pH and dissolved oxygen probes and
an option to input additional sensors via external transmitters• For continuous perfusion processes, vessel weight control feature and the ability to measure 3 pressures from an external perfusion device such as a hollow fiber filter• Data acquisition & real-time trending with built-in OPC server• Alarm condition monitoring including pressure monitoring• Email/text message notifications on out of range process conditions• Fed-batch addition schedule manager• Simple wizards for calibration of probes• Ability to control temperature by electric heater or for jacketed vessels by control of a stand-alone heating / cooling system (TCU)
Product OverviewThe PendoTECH Bioreactor Control System is loaded with features including an easy to use graphical user interface (GUI). The system offers the ability to monitor and control the pH, dissolved oxygen (DO), and temperature with PID control. Using an embedded transmitter from Mettler-Toledo, an industry standard, for monitoring pH and DO with standard probes, it delivers the advanced features and confidence required for measurement and control of the bioreactor. There is also the ability to use in parallel, for strictly monitoring or for process control, external pH and DO sensors. Alarm setpoints are available for all process parameters and also there are notification setpoints designed to be pre-alarm conditions that can be setup to send email/text message alerts so proper adjustments can be made before a critical alarm occurs. Over-pressure of the bioreactor may occur due to a vent filter clogging or other reason and to prevent a vessel failure, pressure monitoring critical. The highly accurate PendoTECH Pressure SensorTM or other full-bridge type sensor provides monitoring of the pressure in the headspace and if a high pressure alarm is triggered, the system will actuate the optional valve signal to relieve pressure and if no change occurs it will go to an alarm mode or there is an option to go to a Standby Mode and heating and mixing remain active. The Run Interlock feature can be used to shut off an integrated perfusion system to automatically prevent the perfusion system from running when the bioreactor is not running. For continuous perfusion processes, there is a vessel weight control feature and the ability to measure 3 pressures from an external perfusion device such as a hollow fiber filter. Also, there is a non-invasive air detector on the base pump tubing that can indicate is the base container is empty. The system can also be configured to run in a fermentation mode where the upper pH limit is controlled by the AUX pump which is PID controlled for acid addition.
Scale
Media Feed Pump
Aux/CircPump
Rotometer Control
MFC
MFC
MFC
MFC Control
Roto-meter
PressureRelief Valve
Data Historian System
Remote Access
Email/Text Notifications
Estop
DirectRTD
Motor Speed Signal
Perfusion device
RunInterlock
(Hollow Fiber lter or other)
Filtrate Pressure
Retenate Pressure
Inlet Pressure
PendoTECH Bioreactor Control & Data Acquisition System
Lab System
Process System
www.pendotech.com Tel: +1-609-799-2299 Copyright © 2018 PendoTECH BRS-REV6
Product Overview
At the heart of the system is the PendoTECH Process Control System platform which is the embedded microcontroller along with its range of input and output cards that can handle the wide range of signals required for monitoring and control of all the features in the bioreactor control system. This same control platform has been used by leading companies in the industry since 2005 for critical bioprocess operations.
Some of the features of the PendoTECH Bioreactor Control System are shown below.
Connection of all inputs and outputs are on the back panel. They are keyed to prevent wrong connections. The Bioreactor Motor/Temperature Control connector carries signals for motor speed control and monitoring and the temperature control relay. The Gas/Pump Box connector carries the Base and Feed pump speed control signal along with the MFC and rotometer control signals along with power to the Gas/Pump Box.
Optional Touch Screen IP66 water-tight PC with Windows 7 GUI software
Panel mount USB & Ethernet connectors
Heater/Motor Control Box
Connects to Bioreactor Motor/Temperature Control connector and receives signals to control
the mixer servo motor and signal to turn the heater on/off
Lab Gas/Pump Box
Drop-down hinged door with ¼ turn screw to
prevent to access specific admin functions
Regulators for the 4 gases
Base and Feed Pump
Connections to the PC
Entire control system housedinside of compact
enclosure with optional mounting brackets for bottom
Control System Hardware Details
Control and powerto gas/pumpbox
Connection for external scales
One power connect for
entire system(100-250-VAC)
There are 4 MFCs for PID control and 2 rotometers (for air overlay and nitrogen sparge) which are only controlled by ON/OFF control. These are housed behind a door which can keep the setpoints secure and also gives easy access to the MFC mounting panel for potential service. The 3 gas outlets are on the rear. The max MFC value can be scaled back to 20% of maximum to give the flexibility to handle a range of vessels with the same MFC.
Lab System
Process System
Front access to pumps (reversible), regulators,
overlay and sparge fittings outlets, and
rotometers (4 inlet gases connect to rear)
www.pendotech.com Tel: +1-609-799-2299
Technical Information
Graphical User Interface• Designed for a touch-screen PC• Simple tab-based navigation• Real-time trending module with advanced features• Pop-up keypad used to change values
Setup View• Change current mode of operation• Select the present value source for pH and dissolved oxygen control• Enter critical alarm setpoints• Enter process notification settings
Summary view of all possible pH & DO2 input present values
Set points for cascade gas control, pH, and temperature
Pressure readings and calculations of delta-P and trans-membrane pressure
(TMP) if using a hollow fiber for perfusion
Indicates present values under control
Estimates of totalized gas volumes
Visual indication of impeller rotatingand bubbles if a gas is on
6 Tabs for Fast and Easy Navigation (system view shown)
Motor speed indicator and ability to change speed
Indicator of currently selected modeof operation
Run/Stop buttons to start and stopcontrol functions
Visual indicator of open gas valves by illuminated indicators and rate display of gas flow setting
Set Base Pump flow rate- pump rotates when running and is under PID control
Feed Pump controlled manually if in Batch, by schedule in Fed-batch, or by weight when
in Perfusion
Air detector to generate notificationif base is tube is empty to prevent
process upset
Visual pressure indicator from zero to critical alarm point
Heater indicator- replaced by TCU graphic if TCU selected for
temperature control
Critical Alarm - Critical alarm that stops pumps/gases appears in RED
Notes - Click here and a pop-up box appears where an electronic note can be entered. The note is written to the data file one time
and time-stamped.
Notifications - Give notifications but do not trigger an alarm
• Writes data to locked file on a real-time basis• Ability to record time-stamped electronic notes to data file• Animated indication of process hardware for remote monitoring process visualization• Manages notification of process conditions out of range
Select Run Mode
Select Sensor for Control of
Setpoint
Enter Critical Alarm Values
Enter Notification Values Here
Currently Selected Mode
Alarm Delay Setting and Alarm Control to either stop the system when an alarm
occurs or go to standby that keeps on mixing and heat
Built in email program to send email or text
messages
Copyright © 2018 PendoTECH BRS-REV6
Trends View
Process Information
Fed Batch Manager
Options to select Auto-scale or Manual scale on all axes
Process parameters including pressure
sensors on perfusion device can be trended
while running
Slide to change cursor value
Powerful tools to zoom, export an image of the current trend and
much more
Quickly compare current values to cursor value
Export the current trend only to open in software such as Excel
Ability to change plot update rate
Information is written to header of data file when data collection is started;
then it becomes un-editable
Alarms set-points-Will stop pumps
Notification points (create no action)
Ability to save/recall frequently used processes
Free test entry field
Enter reference start time via pop-up calendar
Enter schedule of additions based on volume to be added
and feed pump flow rate verified by feed scale
Schedule time indicators
Ability to save and recall schedules
Indicates the location of the data file after it is created
When Start Process Data Collection is selected, a dialog box appears so
a file name and location can be entered. All process data is saved to a CSV file that can be opened later in software
such as Excel.
Completed additions areindicated as completed
www.pendotech.com Tel: +1-609-799-2299
Technical Information
Technical Information
Maintenance View
Ability to change graphical interphase
between a LAB vessel and a Process Vessel
Functions Include:• Probe calibration wizards• Non-invasive Presens patch sensor calibration wizard• Entry of pH and temperature offsets• Set-up Aux/Circulation pump calibration• Reset gas totalizers• Tare Pressure Sensors• Exit program
Probes and Patch sensor on a process vessel
Clicking the button launches the probe calibration wizard
The wizard steps through the calibration process and graphs the probe reading so stabilization can be visualized. It runs the Setup
Air and Setup Nitrogen modes as needed and also has a prompt for the option to do the zero calibration by different methods or to skip
the zero point calibration
100% POINT CALIBRATION STEP 0% POINT CALIBRATION STEP OPTIONS
Copyright © 2018 PendoTECH BRS-REV6
Technical Information
Specifications and Standard AccessoriesDetail Specifications
Enclosure Dimensions (HxWxD) System: 6.125” x 16” x 11.5” (15.5cm x 40.64cm x 29.21cm) plus front hinged door
PROCESS Gas / Pump Box: 11.25” x 11” x 15.5” (28.6cm x 27.9 cm x 39.37cm)
LAB Gas / Pump Box: 19” x 12.25” x 12.25”
Enclosure Weight System: 15 lbs.Gas / Pump Box: 17 lbs.
Enclosure Material 304 stainless steel
Power Requirements 100 - 240 Volts, 50 - 60 Hertz, 6 amp max
Pressure Sensor Input PendoTECH Pressure Sensors +/- 2% of value from 0 - 6 psi, +/- 3% of value from 6 - 30 psi ;
Other full-bridge type sensors optional
Aux/Circulation Pump Control Speed Control: 4 - 20mA, 12 bit (4,096 counts)
E-Stop Interlock 5V Digital input controlled by external relay (normally closed)
Motor Speed Signal Input 0-10VDC, Input impedance of 376 KΩ, 16-bit
Motor Speed Control 0-10VDC, 12-bit, allowed resistance of ≥1KΩ, op-amp output sources and sinks up to 10 mA,
sink current limited at Vo=0 by 39Ω output resistance,
Temperature Input Standard: 100 ohm Pt RTD 3-wire
BR Temperature Control For Electric On/Off: Relay 3 - 48 VDC, up to 3A continuousTCU: RS232 or RS485
External pH and DO inputs 4 -20 mA input, 16-bit (65,536 counts)
Max Flow (SLPM)[with gas regulator for each gas
with maximum pressure of 10psi] * MFC
Overlay Air Sprg* O2 Sprg* CO2 Sprg* N2 Sprg Air Pipe* SM: 10 5 2 1 12 10 LG: 20 10 5 2 12 20 Lab: 0.5 1.5 0.2 0.1 0.2 NA
Run Interlock and Valve Signal Relay 3 - 48 VDC, up to 3A continuous, NO/NC selectable
Scale Inputs RS232 with user selectable scale profiles
External pH and DO monitor 4-20mA input, 16-bit (65,536 counts)
PC Requirements Windows 7, 2 GHz or faster, 2 GB or more of RAM
Example of AUX/Circulation Pump
1) Non-invasive air detector for base tube2) NEMA4 / IP66 Stainless Steel Design All in One PC: - Completely sealed, no external fan - Display- 15” TFT XGA (1024x768)Touch - Resistive touch screen - Windows 7 OEM, multilingual 3) PendoTECH Single Use Pressure Sensors: For full range of sizes see: http://www.pendotech.com/pressure 4) Optional mounting brackets for Thermo SUB Handle (as shown in picture below)5) Optional Presens measurement sensing board and Fiber Optic Probes for Non-Invasive Patch Sensors5) Optional Heater/Motor Control Box for control of motor & temperature to for Lab Benchtop vessels
Base tube air detector
Application InformationThe PendoTECH Bioreactor Control System has been used successfully to control process scale bioreactors including the different size Thermo SUBs from 50L to 2000L and also lab scale vessels down to a few liters. In all designs, the control system is the same which gives ultimate flexibility, only the gas/pump box options vary.
Gas Flow Control- Mass Flow Controllers are used to control the gases for pH and DO control. And within each range of each gas/pump box, the MFC maximum flow can be reduced to 20% of the maximum value of the MFC so 100% PID output can be limited so fine tuning can occur for different vessel sizes across one size gas/pump box. The overlay & nitrogen are on/off control with the flow rate set by rotor meters.
Temperature Monitoring and Control- The temperature input signal standard offering is a direct input of a 100ohm Pt RTD which is used for monitoring and control. The PID control is configurable to either control a relay for an electric heater or to control an external temperature control unit (TCU) that circulates liquid through a jacketed vessel. There are a number of communication protocols for communication with major brands such as the preferred brand LAUDA. Control of the TCU is done by manipulation of the jacket setpoint temperature by a cascade PID loop that compares the jacket temperature setpoint to the vessel RTD. This custom configured PID algorithm allows for cooling of the vessel contents if the TCU has the ability to do cooling.
Pressure Measurement for a Continuous Perfusion Process or Cell Harvest- The system has the ability to input 4 PendoTECH Single Use Pressure Sensor (shown on right)- one for the vent pressure that is integrated to alarm control and three to monitor the performance of an external perfusion device such as a hollow fiber filter. These three pressures (Pin, Pret, and Pfil) are used to calculate delta-P and TMP which are required to measure filter performance. This data is logged to the file and can be trended to measure performance over a lengthy run.
Additional Accessories Details:
Ordering InformationPart Number Description
PDKT-PCS-BRSMF PendoTECH Bioreactor Control System in standard enclosure with front panel cover with PROCESS scale gas/pump box with MFCs for Air, CO2, O2 (vessel size <500L)
PDKT-PCS-BRLMF PendoTECH Bioreactor Control System in standard enclosure with front panel cover with PROCESS scale gas/pump box with MFCs for Air, CO2, O2- ranges (vessel size up to 2000L)
PDKT-PCS-BRBMF PendoTECH Bioreactor Control System in standard enclosure with front panel cover with LAB scale gas/pump box with MFCs for Air, CO2, O2 ranges
Warranty/DisclaimerAll descriptions, representations and/or other information concerning Product on the PendoTECH website and/or contained in PendoTECH’s advertisements, brochures, promotional material, or statements made by employees or sales representatives of PendoTECH are solely for general informational purposes only and are not binding upon PendoTECH. No employee or sales representative of PendoTECH shall have any authority to establish, expand or otherwise modify PendoTECH’s warranty associated with the sale of Product. PendoTECH, LLC makes no warranty or representation regarding whether or not a customer’s end use of any Pen-doTECH product or system infringes the valid intellectual property rights of others. PendoTECH does not direct or instruct customers to use any PendoTECH product or system in combination with particular commercially available pre-sterilized manifolds, remotely operated pinch valves, as such use could possibly be covered by the claims of one or more patents. PendoTECH shall not be liable to BUYER in any manner with respect to Product sold. SELLER, PendoTECH MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY TYPE, EXPRESS OR IMPLIED, AND EXPRESSLY DISCLAIMS AND EXCLUDES ANY REPRESENTATION OR WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR USE, NON-INFRINGEMENT OR WARRANTY ARISING FROM USAGE OF TRADE, COURSE OF DEALING OR PERFORMANCE.” For warranty information see our website at http://www.pendotech.com/warrantywww.pendotech.com Tel: +1-609-799-2299 Copyright © 2018 PendoTECH BRS-REV6